Concrete building construction



CONCRETE BUILDING CONSTRUCTION Filed Sept. 26, 1938 2 Sheets-Sheet 1 I""T" E ll INVENTQR 2 Herberf P/fman Fal/s ATTORNEY June 18, 1940. P, FALLS coucnmn BUILDING cowsmuc'rron FiIed Sept. 26, 19:58

2 Sheets-Sheet 2 R O T E V N f/erberf P/fman al/5 ATTO R N EY Patented June s, 1940 UNITED STATE PATENT C GONC kE-TE BUlzfirltfj floivsTBlUl ii'lo N I r Herbert Pitman Falls, Vancouver, British Columbia, Canada iip icatibh September 26,1938, Serial No. 231,815

, 7 Claims. (cite-1 crete building construction.

An object of the present invention is the pro- ,This invention relates to improvements in convision of a method of erecting concrete buildings 5 with hollow walls without the necessity of using forms or precast blocks or slabs in said walls.

Another object is the provision of a concrete building construction of greater strength than heretofore with the use of lessconcrete. ,0, Another object is the provision of a concrete building construction requiring less timeyand labour and by means of which: the cost of materials may be decreased. A further object is the provision of a mono- 5 lithic wall construction having improved insulation qualities.

I-Ieretofore, hollow concrete walls have been erected but in most instancesit is necessary to erect forms into which. the concrete is poured and after the concrete has set, the forms ,are removed. This entails considerable. labour and the form material is wasted. Another outstancb ing disadvantage of certain constructions is that cores formed, in part at least, of Wood are left in the walls in order to provide air spaces. This wood absorbs moisture and, therefore, swellsl thus tending to deform and crack the wall. This defect is so prominent that ithas rendered this method of construction impracticaL. A further I disadvantage lies in the fact that, after a time,

the wood decays with dry rot.

The present invention overcomes these objec- *tions by providing a concrete building construction wherein forms are unnecessary for v the l; building of the wallsand spacers or cores formed of treated corrugated cardboard, areused whereby a plurality of dead air spaces are provided thus increasing considerably the insulation qualities of the wall. These cores are strong enough p. to retain the concrete in place while the Wall is being erected and, at the sameftime, they will not absorb moisture and swell upto deform the .wall. The cores are intendedto beleft in the wall after it is completed where they act as insulation and they are not subject to. dry rot. A variation of this invention is the use of cores or spacers thatmay be removed for repeated use. In any event, the cost of cores or spacers for any wall is negligible in comparison to the cost in the known methods of construction. i 1

This invention also aims toprovide a novel method of assembling floorslabs with the walls, joists, beams and supporting posts, said floor slabs in themselves being improvedover the knowndloor slabs. In this construction,.bothrthe joists and the beams rest uponthe supporting. posts; and the :joists, :areformed to receive the ends of the floor slabs. The edges of the outer V slabs of the floor and the ends of the outer beams and joists rest upon the top of the wall so that t. the slabs form a seal for theair spaces in the wall; Furthermore, a novel method of erecting the outer staircases is provided whereby considerable labour and time is;.saved.

The present invention is more fully described 1 l in the following specification and illustratedin the accompanying drawings, in which Figure 1 is an enlarged fragmentary sectional view, taken through a wall, showing one form of spacer or core therein,

. .5. Figure 2 is a' vertical section through a wall of a building,

Figure 3 is a fragmentary plan view of two walls at a corner showing the position of the floor slabs, beams and joists at this point, t

Figure 4 is a perspective viewlof an alternative form of spacer or .core, with certain sections broken away. to show the interior thereof,

Figure 5 is a view, partly insection, showing the beams and joists mounted upon the upper end of a supporting post and the floor slabs resting upon the joist,

Figure 6 is an enlarged fragmentary section takenon the line 6-6 of Fig. 3, and

Figure 7 is a side elevation of an outer stair- 0 case, showing. the connection to a wall.

Referring more particularly to'the drawings,

the wall [0 is erected upon a concrete footing M.

This wall is erected in the following manner? A plurality of spaced-apart spacers or cores l2 are placed on end upon the footing II in line with each other. Each core I2 is in the form of a rectangular tube extending substantially the height of astorey of the building and consists of outer and innerlayers I3 and M of cardboard 40 orisimilar material between which is disposed a central layer l5 of corrugated cardboard or the like, each of said layers being waterproofed and treated to prevent bacterial decay. "If desired, braces 16 formed of wood. or other suitable material, may be removably inserted in the cores l2, said braces. extending the full length of the cores.

' After the cores are set in place, U-shaped rods said U-rods. The temperature rods extend substantially the full length of thewall along the inside of the arms of the rods l1 and along the machine.

cement, sand, gravel and water, are mixed in the machine and discharged outwardly under outer surfaces of the cores 12, said arms being disposed beyond each side of the cores. There are a pair of rods l8 extending longitudinally of the wall at approximately the tops of the window side of the cores, and strappings 22'are secured,

thereto, upon which laths or the like are nailed after the wall has been completed. i

The concrete is applied to the above described framework by means of the well known Gunite The necessary ingredients, such as pressure through a nozzle. As the wall is built up, a suitable thickness of concrete is applied'to each side of thecores l2 and, at the same time, webs 23 are formed between the ends of adjacent cores. As the wall nears the tops of the cores, suitable forms are placed thereon at desired intervals and preferably on the webs 23, so that, when the wall is level with the cores, openings are formed therein into which the ends of beams 24 may be placed. The outer ends of the beams 24 extend only to the outer arms of the rods H. The removal of the braces l6 completes the first storey wall. The concrete embeds the cores [2,"

the rods I! and I8, the wire mesh or netting 20,

and the ground pieces 2|, but the strappi'ngs 22' project beyond the inner surface of the con crete. I

Precast reinforced supporting posts 25 are placed at suitable positions in relation to the wall l2 on footings 26. The inner ends of the beams 24 rest. on the upper ends of the posts25, as clearly illustrated in Fig. 2. Precast joists 21 also rest on the upper ends'of theposts 25 between the ends of the beams 24, said joists being re cessed to form shoulders 28' upon which floor slabs 30 rest. These floor slabs extend along the beams 24 to the outer ends thereof and abut against the innervertical arms of the rods I1; It might be added here that the outer ends of the joists 21 extend into the wall Ill in the samemanner as the ends of the beams 24. The joists 27 are reinforced by rods 3| extending longitudinally thereof adjacent the tops and bottoms of these rods are joined together by reinforcing straps 33, see Fig. 5.

By referring to Fig. 6; it will be seen that the floor slabs 3B are formed with" grooves 34 in the edges thereof, into which reinforcing rods 35 project. .The upper surfaces of the floor slabs are slightly smaller than the lower surfaces thereof so that there is a space 31 extending upwardly from the grooves 34 when the slabs are brought together.

When the beams, joists and floor slabs are mounted .in' position, as described, concrete is blown by means of the Gunite machine into the grooves 34 and the spaces 31 between the floor slabs to bind said slabs together. At the same time, concrete is blown into any space there may be between the outer ends of the beams and joists and the walls In and," if necessary, concrete may-be blown between the edges of the door slabs resting on the shoulders 28 of the joists and the joists themselves. With this construction, the outer edges of the floor slabs act as a seal over the upper ends of the cores l2.

The next section of the wall I0 is erected upon the floor slabs 30. The outer arms of the rods I1 of the lower ,wall extend upwardly past the beams 24 and the. floor slabs 30 are tied to the outerarms of the rods I! of the upper section of the wall, as at 40. Reinforcing dowels 4! are tied to the inner arms of the upper rods IT at 42 and extend downwardly through holes formed in the outer floor slabs 30, into thewebs 23 of the lower sectionof the wall, it being understood that these reinforcing dowels are set in place before I the concrete of the lower wall has set. i The upper section is then constructed and erected in the same manner as the lower section. When the concrete of the upper wall is being applied, the outer surface thereof is brought down past the edges of thefloor slabs to join the outer surface of the' lower' wall. After the spacers l6 are removed from the cores, the top of the upper wall is sealed by means of a wall plate 43 through which both arms of the rods I1 extend where they are bent, as at 44. I

The floor 45 is nailed to straps 45 resting on the fioorslabs 30. Laths are nailed to the strappings 22 and plaster is placed onthe laths. In this manner a dead air space is formed between the inner surface of thewall Ill and the laths.

A wall constructed in this manner is reinforced vertically and longitudinally by the U-shaped rods H, the temperature rods l8and the wire mesh or netting 2|). 'The cores 12 form aplurality of dead air spaces 41. 'A'particularfeature of this invention is that-a plurality of dead air cells 48 are formed in each core by the outer and inner layers l3 and I 4 combined with the cen-' tral corrugated layer I5 thereof. Another fact to be considered is that there are six layers of cardboard or similar material in each core which serve" to increase the insulation qualities of the wall."- m

An alternative form of spacer or core 50 is i1- lustrated in Figure 4, which may be used in climates where insulation isnot so essential. The spacer or core 50 'formed'of waterproofed wood or other material, is rectangular in cross section and tapers downwardly from the top to the bottom thereof; Each core is provided with a top5l anda bottom 52,each having a ventilation opening 53 therein. A ring 54' is secured to the top 5| and braces 55 extend longitudinally of the core. The cores 50 extend substantially the full height of each section of the wall and they are withdrawn therefrom by means of the rings 54 whenv the concrete has set, their tapered construction making this possible. These cores may be used repeatedly. t

Fig. 7 illustrates the construction of a concrete outer staircase and verandah. Two'precast, reinforcedside panels 56 spaced apart the desired width of the stairs and verandah, are disposed at right angles to the wall Ill. Precast, reinforced wall slabs 51 are secured by bolts 58 to the wall 10 and to the side panels 56, the.

vided bymeans of which hollow walls may be constructed without the use of the customary ,of or the scope of the claims, and therefore the exact forms shown are tobe taken as illustrative only and not in a limiting sense, and it is desired that only such limitations shall be placed thereon as are disclosed in the prior art'or are set forth in the accompanying claims.

What I claim as myinvention is:

1. In concrete building construction, a wall having therein a plurality of spaced-apart cores in line with each other and extending substantially the height thereof, a plurality of vertical rods disposed beyond each side of the cores and arranged between the ends of adjacent cores,

horizontal temperature rods tied to the vertical rods on each side of the cores, said temperature rods extending the full length of the wall inside of the vertical rods and along the outer surfaces of the cores, wire mesh extending on each side of the cores the full height and length of the wall and tied to the vertical rods on the outside thereof, ground pieces tied to the vertical rods situated on the inner side of the cores, strappings secured to the ground pieces upon which laths or the like may be secured, and concrete embedding the cores, rods, wire mesh and ground pieces,

said strappings projecting beyond the inner surface of the concrete.

2. In concrete building construction, a wall having therein a plurality of spaced-apart cores in line with each other and extending substantially theheight thereof, a plurality of U-shaped rods arranged between the endsof the cores, said rods having vertical arms disposed beyond each side of the cores, horizontal temperature rods tied to the vertical arms above and below the window openings of the wall, said temperature rods extending the full length of the wall inside the vertical arms and along the outer surfaces of the cores, wire mesh extending the full height and length of the wall tied to the vertical arms on the outside thereof on each side of the cores, a ground piece tied to each vertical arm situated on the inner side of the cores, strappings secured to the ground pieces upon which laths or the like may be secured, and concrete embedding the cores, rods, wire mesh and ground pieces, said strappings projecting beyond the inner surface of the concrete.

3. In concrete building construction, a wall having therein a plurality of spaced-apart cores formed of cellular corrugated cardboard or the like, said cores being in line with each other and extending substantially the height of the wall, a plurality of vertical rods disposed beyond each side of the cores and arranged between the ends of adjacent cores, horizontal temperature" rods tied to the vertical rods on each side of the cores, said temperature rods extending the full length of the wall inside the vetical rods and along the outer surfaces of the cores, Wire mesh extending on each side of the cores the full height and length of the wall and tied to the vertical rods on the outside thereof, ground pieces tied to the vertical rods situated on the inner side of the cores, strappings secured to the ground pieces upon which laths or the like may be secured, and concrete embedding the cores, rods, wire mesh and ground pieces, said strappings projecting beyond the inner surface of the concrete.

4. In concrete building construction, a wall having therein a plurality of spaced-apart, rectangularly shaped cores formed of cellular corru gatedgcardboard or the like which has been waterproofed and treatedto prevent bacterial decay, said cores being in line with each other and extending substantially the height of the wall, a plurality of U-shaped rods arranged between theends of the cores, said rods having vertical arms disposed beyond each side of the cores,

horizontal temperature rods tied to the'vertical arms of'the rods, saidtemperature rods extend ing the full length of the wall'inside the vertical arms and along the outer surfaces of the cores, wire mesh extending the full height and length of the wall tied to the vertical arms on the outside thereof, ground pieces tied to the vertical arms situated on the inner side of the cores, strappings secured to the ground pieces upon which laths or the like may be secured, and concrete embedding the cores, rods, wire mesh and ground pieces, said strappings projecting beyond the inner surface of the concrete.

5. In concrete building construction, a wall having therein a plurality of spaced-apart rectangular shaped cores formed of inner and outer layers of cardboard or the like with a central layer of corrugated material forming therein a plurality of dead air cells, said cores being in line with each other and extending substantially the height of the wall, a plurality of vertical rods disposed beyond each side of the cores and arranged between the ends of adjacent cores, horizontal temperature rods tied to the vertical rods on each side of the cores, said temperature rods extending the full length of the wall inside the vertical rods and along the outer surfaces of the cores, wire mesh extending the full height and length of the wall tied to the vertical rods on the outside thereof, ground pieces tied to the vertical rods situated on the inner side of the cores,

strappings secured to the ground pieces upon formed of inner and outer layers of cardboard or the like with a central layer of corrugated material forming therein a plurality of dead air cells, said layers having been waterproofed and treated to prevent bacterial decay,,braces removably inserted in the cores adapted to be removed when the Wall is completed, said cores being in line with each other and extending substantially the height of the wall a plurality of U-shaped rods arranged between the ends of the cores, said rods having vertical arms disposed beyond each side of the cores, horizontal temperature rods tied to the vertical arms above and below the window openings of the wall, said temperature rods extending the full length of the wall inside the ver tical arms and along the outer surfaces of the cores, wire mesh extending the full height and length of the wall tied to the vertical arms on the outside thereof on each side of the cores, a ground piece tied to each vertical arm situated on the inner side of the cores, strappings secured to the ground pieces upon which laths or the like may be secured, and concrete embedding the cores, rods, wire mesh and ground pieces, said strappings projecting beyond the inner surface of the concrete.

7. In concrete building construction, a wall having therein a plurality of spaced-apart, tapered cores formed of wood or the like, each core having a top and bottom with ventilation openings therein and a ring secured to the top by means of which the core may be removed from the wall when the latter is completed, said cores being in line with each other and extending substantially the heightof the wall, a plurality of vertical rods disposed beyond each side of the cores and arranged between the ends of adjacent cores, horizontal temperature rods tied to the vertical-rods on each side of the cores, said temperature rods extending the full length of-the aeoause wall inside the vertical rods and along the outer surfaces of the cores, wire mesh extending on each side of the cores the full height and length of the wall tied to. the vertical rods on the outside thereof, ground pieces tied to the vertical rods situated on the inner side of the cores, strappings secured to the ground pieces upon which laths or the like may be secured and concrete embedding the cores, rods, wire mesh and ground pieces, said strappings projecting beyond the in- 1l ner surface of the concrete.

HERBERT PITMAN FALLS. 

